JP2009268156A - Method of manufacturing coil assembly unit for rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a coil assembly unit for rotary electric machines, which causes less deformation to the coils and which allows a smaller-size device to weave coil wires at higher speed. <P>SOLUTION: In this manufacturing method, the coil forming step, the coil weaving step, and the coil compressing step are performed sequentially. In the coil forming step, the bent portions are formed at both ends of each of slot housing portions of coil wires so that the mutually adjacent linear portions are deviated from each other. Thanks to this deviation of mutually adjacent linear portions, in the weaving step, both turn portions of the pair of formed coil wires can be weaved sequentially with each other without mutual interference when at least one of the formed coil wires is rotated or revolved in the coil weaving step. In the compressing step, the woven coil assembly is compressed by compressing the woven coil so that each bent portion is deformed to be linear to allow the mutually adjacent linear portions to come closer to each other. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a coil assembly for a rotating electrical machine.

Conventionally, various methods have been proposed as a method of manufacturing a coil assembly of a rotating electrical machine. For example, Patent Document 1 proposes a method of simultaneously winding a plurality of coil wires using a pair of opposed plate-shaped cores. In Patent Document 2, another coil wire is rotated around its axis by 90 degrees with respect to one coil wire formed in a triangular wave shape by a winding process, and the overlap is made by a half turn. By repeating the step of moving in the direction of one coil so as to increase and the step of rotating the other coil wire rod by 90 degrees around its axis, the other coil wire rod is sequentially turned into one coil wire rod by half a turn. A method of weaving is proposed.
Japanese Patent Laid-Open No. 2002-176552 JP 2004-104841 A

  As a method of weaving a plurality of coil wire materials having a plurality of turn portions, the following methods can be further considered. For example, as is done with a known strand wire machine, another coil wire is rotated (revolved) around one fixed coil wire, and the coil pitch is moved in the coil longitudinal direction by one revolution. It is a knitting method or a method of holding two knitted wire rods at a predetermined angle around a knitted portion and rotating (revolving) around each other to knit each other.

  However, in these methods, in order to avoid interference between the turn portions, it is necessary to set a large angle between the axis of one coil wire and the axis of another coil wire, and the coil wire is deformed. There was a problem that it was easy. In particular, when a coil assembly for a motor that is long in the axial direction is manufactured, the straight portion of the slot accommodating portion that is formed in a linear shape of the coil wire becomes long, so that deformation becomes large during braiding. If the coil wire is deformed during braiding as described above, the braided coil becomes distorted and a desired coil assembly cannot be obtained.

  Further, in the case of the above braiding method, there is a problem that the apparatus size is increased because the coil wire is largely rotated, the apparatus cost is increased, and it is difficult to increase the speed.

  The present invention has been made in view of the above circumstances, and it is an object of the present invention to provide a method for manufacturing a coil assembly of a rotating electrical machine that can be knitted at high speed using a small device with little deformation of the coil. It is what.

  Hereinafter, each means suitable for solving the above-described problems will be described while adding effects and the like as necessary.

1. A plurality of coil wire rods having a plurality of slot accommodating portions formed in a straight line and arranged in parallel and a plurality of turn portions respectively connecting one end portion and the other end portion of the adjacent slot accommodating portions to each other. A method of manufacturing a coil assembly of a rotating electrical machine by braiding,
A coil forming step of forming bent portions at both ends of each of the slot accommodating portions of the coil wire so that the adjacent slot accommodating portions bend away from each other;
Each of the formed coil wire rods intersects the pair of turn portions at one end side of the pair of formed coil wire rods formed with the bent portions, and the angle formed by each axis of each of the formed coil wire wires is within a predetermined range. In a state where the other end side of the wire is held, a braiding step of rotating at least one of the pair of the formed coil wire rods and sequentially intersecting the turn portions of the pair of the formed coil wire rods,
The adjacent slot accommodating portions are brought closer to each other by applying a process to linearly deform the bent portions formed in the slot accommodating portions on the knitted coil after the knitting process is completed. A coil shrinking step to deform
A coil assembly manufacturing method for a rotating electrical machine, comprising:

  In the means 1, a coil forming process, a braiding process, and a coil shrinking process are sequentially performed. In the coil forming step, bent portions are formed at both ends of each slot accommodating portion of the coil wire so that adjacent slot accommodating portions are bent away from each other. By forming the bent portion, the one end portion is deformed so that the other end side of the adjacent slot accommodating portions connected at one end is opened.

  Thereby, when performing the next braiding process, by rotating at least any one of a pair of shaping coil wires, and making each turn part of a pair of shaping coil wires cross sequentially, each shaping coil wire The turn parts can be knitted without interfering with each other. Therefore, it is possible to set the angle formed by each axis of each formed coil wire to be smaller than the case where the above-described bent portion is not formed in each slot accommodating portion of the coil wire, and deformation that occurs when the coil wire is knitted. Can be reduced.

  In this braiding process, another coil wire rod is rotated (revolved) around one fixed coil wire rod or held at a predetermined angle around the braided portion of the two coil wire rods, A knitting method such as a method of rotating (revolving) the knitting and knitting, or a method of rotating a pair of formed coil wires around the respective axes in the same direction can be appropriately selected and employed.

  Then, in the next coil shrinking step, adjacent slots are accommodated by performing a process of deforming each bent portion formed in each slot accommodating portion linearly on the braided coil after the end of the braiding step. The parts are deformed so as to approach each other. As a result, a predetermined braided coil having slot accommodating portions that are linearly deformed and arranged substantially in parallel is obtained.

  Therefore, according to the means 1, in the coil forming step, the bent portions are formed at both ends of each slot accommodating portion of the coil wire so that adjacent slot accommodating portions are bent away from each other. In the braiding process, the braiding can be performed without interference between the turn portions of the formed coil wire. In particular, when the number of formed coil wires to be knitted is large, the interval width between adjacent slot accommodating portions is narrowed, so that interference between turn portions can be advantageously avoided. Thereby, it becomes possible to set small the angle which each axis line of each shaping | molding coil wire forms, and can reduce the deformation | transformation which arises at the time of braiding of a shaping | molding coil wire.

  In addition, since a small device can be used as the rotating device used in the braiding process, the manufacturing apparatus can be reduced in size and cost. Further, since the rotating operation of the formed coil wire can be reduced, it can be easily rotated at a high speed, and the braiding can be speeded up.

  The coil assembly manufactured by the manufacturing method of the present means includes, for example, a rotating electric machine having a rotor that forms a plurality of magnetic poles that are alternately different in the circumferential direction and a stator that faces the inner circumferential side or the outer circumferential side. The multi-phase stator winding is configured by a plurality of slots formed in a circumferential direction of the stator core, which is formed of a wire having a substantially rectangular cross section. In addition, the coil wire has, for example, a slot accommodating portion installed in a slot having a different circumferential direction, and a turn portion that connects one end and the other end of the slot accommodating portion outside the slot. The projecting part of the turn part projecting from the slot is formed in a crank shape facing the slots where the coil wire material is installed. Further, the substantially central portion of the turn portion may be formed in a crank shape without twisting, and the substantially central portion where the crank shape of the coil wire is formed is shifted to the crank shape by the approximate width of the wire. It may be. The coil wire may be formed continuously over the entire circumference of the stator core.

  2. 2. The coil set for a rotating electrical machine according to claim 1, wherein the coil wire material is one in which the length of each slot accommodating portion is equal to or longer than the interval width between adjacent slot accommodating portions. Three-dimensional manufacturing method.

  According to the means 2, when the braiding process is performed, the interference between the turn portions of the coil wire rods increases as the length of each slot receptacle portion becomes longer than the interval width between the adjacent slot receptacle portions of the coil wire rod. Since it becomes easy to occur, based on providing a bent part in each slot accommodating part in a coil formation process, the deformation inhibitory effect of the forming coil wire material in a braiding process can be exhibited effectively.

  3. The coil of the rotating electrical machine according to means 1 or 2, wherein, in the coil forming step, each of the bent portions is formed at a position separated from a corner portion where each of the slot accommodating portions and each of the turn portions intersects. Assembly manufacturing method.

  According to the means 3, when forming each bent portion, the angle of the corner portion where each slot accommodating portion and each turn portion intersect can be prevented from changing. For this reason, in the coil shrinking process, when performing the process of deforming each bent portion in a straight line, the angle of the corner where each slot accommodating portion and each turn portion intersect may be maintained as it is. The process which deform | transforms a part into a linear form can be performed easily. Further, by performing a simple process of deforming each bent portion in a straight line, the slot accommodating portions can be easily brought into a substantially parallel state.

  4). In the coil forming step, the bending angle of each bent portion formed on one end side of each slot accommodating portion is equal to the bending angle of each bent portion formed on the other end side. The manufacturing method of a coil assembly for a rotating electrical machine according to any one of claims 1 to 3.

  According to the means 4, since the linear portions outside the respective bent portions formed at both ends of each slot accommodating portion are substantially parallel, the straight line state is maintained without bending the axis of the formed coil wire rod. Can do.

  5). In each of the coil forming steps, each of the bent portions is configured such that an opening angle between adjacent slot accommodating portions is equal to or greater than an angle formed by each axis of each of the forming coil wires set in the braiding step. The coil assembly manufacturing method for a rotating electrical machine according to any one of means 1 to 4, wherein:

  According to the means 5, by increasing the opening angle of the adjacent slot accommodating portions, it is possible to set the angle formed by each axis of each formed coil wire set in the braiding process to be small. Thereby, the deformation | transformation which arises at the time of braiding of a shaping | molding coil wire can be suppressed advantageously. The opening angle of the adjacent slot accommodating portions here refers to the adjacent slots centering on one end portion of the slot accommodating portion in the adjacent slot accommodating portions whose one end portions are connected to each other by one turn portion. The angle formed by the housing part.

  Hereinafter, each embodiment which actualized the coil assembly manufacturing method of the rotary electric machine of the present invention is described concretely, referring to drawings. First, a schematic configuration of the stator 10 of the rotating electrical machine to which the coil assembly 20 manufactured by the manufacturing method of each embodiment of the present invention is applied will be described. FIG. 1 is a perspective view showing an appearance of a stator 10 of a rotating electrical machine to which a coil assembly 20 is applied, and (B) is a view of the stator 10 as viewed from the side. FIG. 2 is an enlarged perspective view showing a part of the stator 10.

  A stator 10 shown in FIG. 1 is used, for example, in a rotating electrical machine that also serves as a motor and a generator of a vehicle. The stator 10 rotatably accommodates a rotor (not shown) on the inner peripheral side. The rotor is formed with a plurality of magnetic poles alternately different in the circumferential direction by a permanent magnet on the outer peripheral side facing the inner peripheral side of the stator 10. The stator core 12 is formed in an annular shape by laminating magnetic steel plates having a predetermined thickness in the axial direction. As shown in FIG. 2, the stator core 12 includes a plurality of sets of slots 14, 15 in the circumferential direction on the inner peripheral side of the stator core 12. Is formed. The coil assembly 20 as a stator winding is a three-phase winding, and a stator winding for each phase is installed in a pair of slots 14 and 15 adjacent in the circumferential direction. Then, stator windings of different phases are installed in three sets of slots 14 and 15 adjacent to each other in the circumferential direction with the slots 14 and 15 as a set.

  Next, the configuration of the coil assembly 20 will be described. FIG. 3 is a perspective view showing the appearance of the coil assembly 20. FIG. 4 is a front view showing a coil end portion of the coil assembly 20. FIG. 5 is a front view showing the overall shape of the coil wire 30. FIG. 6 is a cross-sectional view of the coil wire 30. FIG. 7 is a perspective view showing the shape of the turn part 42 of the coil wire 30.

  As shown in FIG. 5, the coil wire 30 of the coil assembly 20 includes a plurality of turn portions 42 formed at a predetermined pitch, and one piece has a length of about 3 m. Further, as shown in FIG. 6, the coil wire 30 is formed of a copper conductor 32 and an insulating coating composed of an inner layer 34 and an outer layer 36 that cover the outer periphery of the conductor 32 and insulate the conductor 32. The inner layer 34 covers the outer periphery of the conductor 32, and the outer layer 36 covers the outer periphery of the inner layer 34. The thickness of the insulating coating including the inner layer 34 and the outer layer 36 is set between 100 μm and 200 μm. As described above, since the insulating coating composed of the inner layer 34 and the outer layer 36 is thick, it is not necessary to insulate the coil wire materials 30 with insulating paper or the like sandwiched between the coil wire materials 30.

  As shown in FIG. 2, the coil wire 30 protrudes out of the stator core 12 from the slots 14 and 15 and the slot accommodating portions 40 installed in the slots 14 and 15 of the stator core 12, and differs in the circumferential direction. And a turn portion 42 that connects the slot accommodating portions 40 installed in the slots, and is wound around the stator core 12 to form a stator winding (coil assembly) 20. ing. The turn portions 42 are formed on both sides of the stator core 12 in the axial direction. In the coil wire 30, odd-numbered turn portions and even-numbered turn portions are alternately provided at positions that are 180 degrees out of phase around the axis.

  As shown in FIG. 7, a crank portion 44 without twisting is formed at a substantially central portion of the turn portion 42. The crank portion 44 is formed in a crank shape along the end surface 13 of the stator core 12.

  Next, the manufacturing method of the coil assembly 20 of this embodiment is demonstrated. FIG. 8 is an explanatory view showing a coil forming process in the present embodiment. FIG. 9 is an explanatory diagram showing a knitting process in the present embodiment. FIG. 10 is a front view showing a part of the knitted coil after completion of the knitting process in the present embodiment. FIG. 11 is an explanatory diagram showing a coil contraction process in the present embodiment. 12 is a front view showing a part of the coil after the end of the coil contraction process in the present embodiment.

  In the present embodiment, a coil forming process, a braiding process, and a coil shrinking process are sequentially performed. In the coil forming step, as shown in FIG. 8, a linear wire 30A is formed by a forming die 51 to form a formed coil wire 30B having a predetermined shape. In this formed coil wire 30B, linear slot accommodating portions 40 and stepped turn portions 42 are formed alternately and continuously, and bent portions 47 are formed at both ends of each slot accommodating portion 40. .

  The bent portion 47 is formed so as to bend in a direction in which adjacent slot accommodating portions 40 move away from each other. That is, in the adjacent slot accommodating part 40 where one end part is connected by one turn part 42, the bending part 47 is formed so that the other end side of the slot accommodating part 40 may open. The opening angle α of the adjacent slot accommodating portions 40 is 40 degrees. Each bent portion 47 is formed at a position separated from the corner so that the intersection angle of the corner where each slot accommodating portion 40 and each turn portion 42 intersect does not change.

  In addition, the bending angle of each bending portion 47 formed on one end side of each slot accommodating portion 40 is the same as the bending angle of each bending portion 47 formed on the other end side. Thereby, since the linear part which exists in the outer side of each bending part 47 formed in the both ends of each slot accommodating part 40 becomes substantially parallel, it has become a linear state, without the axis line of the shaping | molding coil wire 30B curving. . In addition, each slot accommodating part 40 is made longer than the space | interval width of adjacent slot accommodating parts 40. FIG. Further, the odd-numbered turn portions 42A and the even-numbered turn portions 42B are alternately provided at positions that are 180 degrees out of phase around the axis.

  In the next weaving step, as shown in FIG. 9, the pair of turn portions 42 intersect each other at one end side of the pair of formed coil wire rods 30B, and the angle formed by each axis of each formed coil wire rod 30B (hereinafter, “ The other end of each molded coil wire 30B is held so that θ is within a predetermined range (set to about 15 degrees in this embodiment). In this state, for example, when the pair of formed coil wires 30B are rotated in the same direction around the respective axes, the respective turn portions 42 of the pair of formed coil wires 30B sequentially intersect from one end side to the other end side. Weaving is performed by following. Thereafter, knitting was performed in the same manner to obtain a braided coil 30C shown in FIG. 10 in which a total of 12 formed coil wire rods 30B were knitted.

  Then, in the next coil shrinking step, as shown in FIG. 11, with respect to the braided coil 30C after the braiding step, the portions where the bent portions 47 at both ends of the slot accommodating portions 40 are formed, Two coil holders 55 and 56 are installed so as to be clamped, and the coil holder 55 is operated to deform each bent portion 47 into a straight line. In this case, in FIG. 11, the location of the first turn portion group located at the leftmost end of the braided coil 30C is fixed. When the coil holders 55 and 56 are operated, the bent portions 47 are linearly deformed, so that adjacent slot accommodating portions are deformed so as to approach each other.

  Accordingly, the second turn part group A, the third turn part group B, and the fourth turn part group C from the left end simultaneously move in the left direction in FIG. At this time, if the moving amount of the turn part group A is 1, the moving amount of the turn part group B is 2, and the moving amount of the turn part group C is 3. As a result, as shown in FIG. 12, a predetermined braided coil 30D having a slot accommodating portion 40 that is deformed linearly and becomes substantially parallel is obtained. And while joining the edge part of each coil wire 30 in several places, the coil assembly 20 as shown in FIG. 3 is completed by shape | molding the whole in a donut shape.

  As described above, according to the present embodiment, in the coil forming step, the bent portions 47 are bent at both ends of each slot accommodating portion 40 of the coil wire 30 so that the adjacent slot accommodating portions 40 bend away from each other. Therefore, in the braiding process, the braiding can be performed without interference between the turn portions 42 of the molded coil wire 30B. As a result, the braiding angle θ can be set small, and deformation that occurs when the forming coil wire 30B is braided can be minimized.

  In addition, since a small device can be used as the rotating device used in the braiding process, the manufacturing apparatus can be reduced in size and cost. Furthermore, since the rotating operation of the formed coil wire 30B can be reduced, it can be easily rotated at a high speed, and the braiding can be speeded up.

  In particular, in the present embodiment, when the bent portions 47 are formed at both ends of each slot accommodating portion 40 in the coil forming step, the opening angle α of the adjacent slot accommodating portions 40 is set in the braiding step. It is set to be larger than the braiding angle θ. Therefore, since the braiding angle θ can be set smaller by increasing the opening angle α, it is possible to advantageously suppress deformation that occurs when the formed coil wire 30B is braided.

  The relationship between the opening angle α of the formed coil wire 30B and the braid angle θ at which interference between the turn portions does not occur using the formed coil wire 30B that has been knitted in the above knitting process. The result shown in 13 was obtained. When the opening angle α was 0 degree (see FIG. 14), the braiding angle θ at which no interference between the turn portions occurred was 50 degrees. When the opening angle α was 25 degrees (see FIG. 15), the braiding angle θ at which interference between the turn portions did not occur was 25 degrees. Further, as in the above embodiment, when the opening angle α is 40 degrees (see FIG. 9), the knitting angle θ at which interference between the turn portions does not occur is 15 degrees. Further, when the opening angle α is 60 degrees (see FIG. 16), the braiding angle θ at which interference between the turn portions does not occur is 10 degrees.

  From the above, it can be seen that the larger the opening angle α, the smaller the braiding angle θ. Therefore, a range in which the ratio of the braiding angle θ to the opening angle α is 1 or less is considered a preferable range.

(A) is the top view of the stator of the rotary electric machine which applied the coil assembly manufactured by the method of one Embodiment of this invention, (B) is the figure which looked at the stator from the side. It is a perspective view which expands and shows a part of stator. It is a perspective view which shows the external appearance of a coil assembly. It is a front view which shows the coil end part of a coil assembly. It is a front view which shows the whole shape of a coil wire. It is sectional drawing of a coil wire. It is a perspective view which shows the shape of the turn part of a coil wire. It is explanatory drawing which shows the coil formation process in embodiment of this invention. It is explanatory drawing which shows the braiding process in embodiment of this invention. It is a front view which shows a part of knitted coil after the end of the knitting process in the embodiment of the present invention. It is explanatory drawing which shows the coil contraction process in embodiment of this invention, (A) is a left view, (B) is a front view. It is a front view which shows a part of coil after completion | finish of the coil contraction process in embodiment of this invention. It is a graph which shows the relationship between opening angle (alpha) and braiding angle (theta). It is explanatory drawing at the time of opening angle (alpha) being 0 degree | times. It is explanatory drawing when opening angle (alpha) is 25 degree | times. It is explanatory drawing when opening angle (alpha) is 60 degree | times.

Explanation of symbols

DESCRIPTION OF SYMBOLS 12 ... Stator core 14,15 ... Slot 20 ... Coil assembly 30 ... Coil wire 30A ... Wire 30B ... Molded coil wire 30C ... Braided coil 30D ... Braided coil 40 ... Slot accommodating part 42 ... Turn part 47 ... Bending Part 51: Mold 55, 56: Coil holder α: Opening angle of the formed coil wire θ: Angle formed by each axis of each coil wire

Claims (5)

A plurality of coil wire rods having a plurality of slot accommodating portions formed in a straight line and arranged in parallel and a plurality of turn portions respectively connecting one end portion and the other end portion of the adjacent slot accommodating portions to each other. A method of manufacturing a coil assembly of a rotating electrical machine by braiding,
A coil forming step of forming bent portions at both ends of each of the slot accommodating portions of the coil wire so that the adjacent slot accommodating portions bend away from each other;
Each of the formed coil wire rods intersects the pair of turn portions at one end side of the pair of formed coil wire rods formed with the bent portions, and the angle formed by each axis of each of the formed coil wire wires is within a predetermined range. In a state where the other end side of the wire is held, a braiding step of rotating at least one of the pair of the formed coil wire rods and sequentially intersecting the turn portions of the pair of the formed coil wire rods,
The adjacent slot accommodating portions are brought closer to each other by applying a process to linearly deform the bent portions formed in the slot accommodating portions on the knitted coil after the knitting process is completed. A coil shrinking step to deform
A coil assembly manufacturing method for a rotating electrical machine, comprising:   The coil of the rotating electrical machine according to claim 1, wherein the coil wire is used in which the length of each slot accommodating portion is equal to or longer than the interval width between adjacent slot accommodating portions. Assembly manufacturing method.   3. The rotating electrical machine according to claim 1, wherein in the coil forming step, each of the bent portions is formed at a position separated from a corner portion where each of the slot accommodating portions and each of the turn portions intersects. Coil assembly manufacturing method.   In the coil forming step, a bending angle of each of the bent portions formed on one end side of each of the slot accommodating portions is equal to a bending angle of each of the bent portions formed on the other end side. The coil assembly manufacturing method for a rotating electrical machine according to any one of Items 1 to 3.   In each of the coil forming steps, each of the bent portions is configured such that an opening angle between adjacent slot accommodating portions is equal to or greater than an angle formed by each axis of each of the forming coil wires set in the braiding step. The coil assembly manufacturing method for a rotating electric machine according to any one of claims 1 to 4, wherein the coil assembly is formed.

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